Kenmore 795.78402.804 Service Manual Download Page 2

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ECN (Engineering Change Number)

Rev.803
•Change Cover Lower (improve structure) &

Change Cover PCB (improve)

Rev.804
•Change model to Barrierless type

Accomplish DOE

Summary of Contents for 795.78402.804

Page 1: ...04 795 78413 804 795 78416 804 795 78419 804 REFRIGERATOR SERVICE MANUAL CAUTION BEFORE SERVICING THE PRODUCT READ THE SAFETY PRECAUTIONS IN THIS MANUAL Printed in Mexico www sears com Sears Roebuck and Co Hoffman Estates IL 60179 U S A MFL53274410 BOTTOM FREEZER REFRIGERATOR ...

Page 2: ...ECN Engineering Change Number Rev 803 Change Cover Lower improve structure Change Cover PCB improve Rev 804 Change model to Barrierless type Accomplish DOE ...

Page 3: ... ICEMAKER 7 1 Operation principle 7 2 Ice maker functions 7 3 Defect diagnosis function 8 DESCRIPTION OF FUNCTION CIRCUIT OF MICOM 8 1 Function 8 2 PCB function 8 3 Troubleshooting 8 4 Main PWB assembly and parts list 9 EXPLODED VIEW AND REPLACEMENT PART LIST 2 3 6 7 7 9 10 11 11 12 12 12 13 13 13 13 14 14 14 15 15 16 17 18 18 19 19 19 19 20 21 22 22 23 24 26 28 28 28 29 30 31 31 37 42 44 46 2 Ple...

Page 4: ... this information nor can it assume any liability in connection with its use ELECTRICAL SPECIFICATIONS Freezer temperature control Middle setting Defrost Control Defrost Thermostat Electrical Rating 115VAC 60Hz Maximum Current Leakage Maximum Ground Path Resistance Energy Consumption 1 4 NO LOAD PERFORMANCE Control Position MID MID 6 F to 8 F Automatic 50 F 1 5 A 0 5mA 0 14 Ohms 22 5 cu ft 670kWh ...

Page 5: ...citor Compressor Hi Side Evaporator Lo Side Condenser Dryer Condenser Fan Motor Temperature Control Main Control Duct Assy Connector 1 8 AIR FLOW EBG42993601 EAF39584205 6615JB2005C 5300JB1100J 4681JB1027C 0CZZJB2012K TCA31748003 5421JJ1001B 5403JJ1007A 5851JA2007E 4681JB1029J EBR43358504 EBR41956108 ADJ36834101 EVAPORATOR EVAPORATOR FAN DRYER HOT LOOP COMPRESSOR CONDENSER CONDENSER FAN FRESH FOOD...

Page 6: ...epth w o Door Depth Total with Door Open Height to Top of Case Height to Top of Door Hinge Width Width door open 90 deg w o handle Width door open 90 deg w handle A B C D E F G H I Description 7840 7841 28 36 41 45 32 67 11 16 69 1 16 34 5 8 32 1 8 ...

Page 7: ...Filter Inside Modular Door Bins Refrigerator Shelves Pull out Drawer Turbo Motor Durabase Divider IceBin WaterTankCover Snack Pan EggBox Dairy Corner Can Rack On some models B I L C Ice Room Ice Maker and Ice Bucket A O G P Q H F E D J K Ice Bucket Ice Room Door Freezer Light N Crisper M 2 PARTS IDENTIFICATION A B H P O G N J K I C E D C Q F M L Use this section to become more familiar with the pa...

Page 8: ...nect door switch wire 2 Pull out the tube 4 CAUTION If a tube end is deformed or worn out cut the damaged portion away Disconnect wire harness 5 Remove the ground screw 6 Loosen screws 7 and lift off the top hinge 8 CAUTION When removing top hinge be careful that the door does not fall forward Right Door Loosen the cover screw 1 Disconnect door switch wire 2 Place the door on a non scratching surf...

Page 9: ...t the wire harness 5 Connect the door switch wire 2 Tighten the cover screw 1 Left Door Lower the door onto the middle hinge pin 10 Make sure the door is aligned with the cabinet Replace the top hinge 8 installing hinge screws 7 to secure it Make sure the gasket on the door is flush against the cabinet and is not folded Support the door on the handle side while tightening And make sure the door is...

Page 10: ...kes it easier to adjust the screws 3 Open both doors again and check to make sure that they close easily If not tilt the refrigerator slightly more to the rear by turning both leveling screws clockwise It may take several more turns and you should turn both leveling screws the same amount 4 Re adjust if necessary 5 Replace the base cover NOTE Your new refrigerator is uniquely designed with two fre...

Page 11: ... door 2 Door Gasket Replacement 1 Insert gasket bracket clips 1 Insert gasket bracket edge beneath door frame edge 2 Turn upper gasket bracket spring so that the spring ends are in the door channel 3 Push in clip until you hear it snap securely into place 4 Push in remaining clip until you hear it snap securely into place Note Make sure that no part of gasket bracket edge protrudes from beneath do...

Page 12: ...Assembly Replacement 1 Remove the plastic guide for slides on left side by unscrewing phillips head screws 2 Pull the grille forward as shown in the second picture 3 Disconnect wire harness of the grille 4 Remove the scroll assembly by loosening 3 screws 3 5 DEFROST CONTROL ASSEMBLY Defrost Control assembly consists of Defrost Sensor and FUSE M The Defrost Sensor works to defrost automatically It ...

Page 13: ...p 1 Unplug refrigerator power cord form outlet 2 Gently pry the lamp cover loose in the back as shown Rotate forward to remove the front tabs 3 Make sure the bulb is cool to the touch Turn the bulb counterclockwise to remove 4 Replace with a new 60 watt appliance bulb 5 Insert tabs on front of cover into slots in freezer ceiling Push cover up to snap back into place 3 7 MULTI DUCT 1 Remove the upp...

Page 14: ...l that the lead wire does not come out and the water tube is not pinched by the dispenser cover as shown in the picture below 3 10 DISPLAY PWB REPLACEMENT 1 Pull up and out on the dispenser cover to remove 2 Follow the steps in the pictures 3 11 FUNNEL REPLACEMENT 1 Pull up and out on the dispenser cover to remove 2 Disconnect the wire harness 3 Replace in reverse order 3 12 SUB PWB FOR WORKING DI...

Page 15: ...OR REPLACEMENT 1 Loosen the front screw as shown in the picture 2 Lift up the hinge with one hand 3 Pull out the Ice Corner Door with the other hand 3 15 ICEMAKER ASSEMBLY 1 Loosen two screws as shown in the first picture 2 Disconnect the wire harness ground screw replace theIcemaker assembly in the reverse order of removal 3 It separates a ground connection screw Hinge 14 ...

Page 16: ...ver assembly There is a auger motor on the back as shown in the picture Auger Motor 15 3 17 HOW TO REMOVE A DOOR ICE BIN 2 Lift the lower part slightly 1 Insert the Ice Bin slightly tilting it to avoid touching the Icemaker especially ice maker lever Insert the ice bucket carefully avoid contacing the automatic shut off arm 1 2 1 Grip the handles as shown in the picture 3 18 HOW TO INSERT A DOOR I...

Page 17: ...ighten the screws Rail tabes Door Supports Screws Make sure you have a right rail cover for each side Right Rail cover Left Rail cover Fig 15 Fig 16 Fig 17 Align the top holes of the rail cover with the top holes of the door supports to assemble the rail cover Fig 18 Verify the hole s assembly With the rails pulled out to full extension insert the durabase in the rail assembly Durabase WARNING To ...

Page 18: ...g it from rail system Press both hangers with yours thumbs to lift it up Durabase Fig 22 Fig 23 Separate the left and right rail cover Fig 24 screw Remove the screws of the rail on both sides Fig 25 With both hands hold both sides of the door and pull it up to separate it from the rails Fig 29 Fig 28 Fig 26 Push rails back into drawe cavity With both hands hold the center of the bar and push it in...

Page 19: ...l care for the following details 1 Be careful not to bend the tube during assembly 2 Press the WATER DISPENSER button until water pours out and check for leakage in the CONNECTOR TUBE It differs by the water pressure but usually takes about 2 minutes until water pours out MOTOR COVER FAN ASSEMBLY MOTOR 3 21 GLIDE OUT DRAWER To remove lift basket up and pull out straight out 2 1 To Install pull bot...

Page 20: ...ent flow to both the start winding and main winding 4 2 3 PTC Applied Circuit Diagram Starting Method for the Motor 4 2 4 Motor Restarting and PTC Cooling 1 It requires approximately 5 minutes for the pressure to equalize before the compressor can restart 2 The PTC device generates heat during operation Therefore it must be allowed to cool before the compressor can restart 4 2 5 Relation of PTC St...

Page 21: ... REMOVE THE COVER PTC 1 Remove the Cover Back M C 2 Remove the screw on Cover PTC 3 Remove two Housings on upper part of Cover PTC 4 T ake out the cover PTC from upper to lower position like 1 5 Turn 45 in the direction of 2 and take it out 6 Assembly in reverse order of disassembly 1 2 Part Customer part number Lot code date code 330 FBYY S1 BOX98 12345678 termination part number Electrical chara...

Page 22: ...SOR F SENSOR CON2 2 BK STEPPING PLUG TYPE LIVE NEUTRAL BK WH 2 1 RD 4 RD BN 6 BN 5 BL ICING SENSOR CON5 BL PWB ASSEMBLY DISPLAY CON104 1 2 1 PK SB 3 2 CON101 RT SENSOR PLUG TYPE CAPACITOR PART P T C AND COMP ACCESSORIES ON CIRCUIT DIAGRAM ARE SUBJECT TO CHANGE IN DIFFERENT LOCALITIES AND MODEL TYPE GN YL P T C OPTION DOOR DUCT HTR LED 1 WH RD LQ COMP BL CR L BK EG COMP 3 2 BL WH e 4 6 f N OLP DISP...

Page 23: ...pplied voltage isn t in acceptable range 115V 10 Remove PTC Starter from compressor and measure voltage between T erminal C of compressor and terminal 5 or 6 of PTC Check resistance of two terminals in PTC Starter Check resistance of two terminals in OLP Check the power supply under load Compressor attempting to re start after being off for 5 minutes Check resistance of PTC Starter Check OLP Check...

Page 24: ...a T ester Figure 1 Observation value is 115V 60Hz 6 8 20 The resistance value is 0 short or open Check another electric component Replace OLP Replace PTC Starter Figure 1 Figure 2 Normal operation of compressor is impossible or poor Separate OLP from compressor and check resistance value between two terminals of OLP whit a tester Figure 2 23 ...

Page 25: ...ity Replace indicated component Advise customer that the power supply needs to be checked by an electrician Replace indicated component Cause Check voltage at starting devices Check current flowing in sub coil of Compressor Check rating of OLP Fan motor doesn t run Wire is open or shorted Coil is shorted or open Open Open Replace defrost heater Replace indicated component Replace indicated compone...

Page 26: ...re high Are any unnecessary objects placed Check if the Tray Drip is not firmly fixed Check if the cover of the compressor enclosure in the front lower side is taken out Check if the door gasket is dirty with an item like juice Check if the inside of the unit is dirty The unit smells of plastic Plug into the outlet Set the switch to ON Replace the fuse If the voltage is low correct the wiring Plac...

Page 27: ... not heard and frost isn t formed Flowing sound of refrigerant is not heard and frost melts Low flowing sound of refrigerant is heard and frost forms in inlet only Flowing sound of refrigernat is not heard and there is no frost A little higher than ambient temperature Refrigerant level is low due to a leak Normal cooling is possible by restoring the normal amount of refrigerant and repairing the l...

Page 28: ... Very Fast Inefficient Compressor Partial Restriction Complete Restriction Equalization Test Condenser Temperature None Very Fast Very Slow Very Slow Hotter than Normal Air Low Side Leak Loss of Change Compressor Not Pumping Cap Tube Sound Room Temperature Trace of Oil Undercharge Leak Yes No Faint Fast None to Weak The equalization test is trying to restart a compressor using a start kit after it...

Page 29: ... until water becomes ICE after starting the icemaking operation Runs MOTOR to drop ice from the tray into the ICE BIN During harvest mode check if the ice bin is full Performs Ice Making Mode after supplying water by operating the SOLENOID in ICE VALVE To operate LINE and SERVICE press and hold the Fill Key for 3 seconds The icemaker will run through 3 stages Harvest Fill Icemaking Reaches Start P...

Page 30: ...e in the ice storage bin while rotating with the EJECTOR A Ice storage bin is full The EJECTOR stops heater off B Ice storage bin is not full The EJECTOR rotates twice to open for ice If the EJECTOR does not rotate once within 5 minutes in B mode separate heater control mode starts operating to prevent the EJECTOR from being constrained It is recommended that the user open for ice to return to nor...

Page 31: ...pre test setting Diagnosis TABLE 7 3 DEFECT DIAGNOSIS FUNCTION 7 3 1 ERROR CODES shown on Ice Maker water supply control panel STAGE ITEMS INDICATOR REMARKS 1 2 3 4 5 6 HEATER MOTOR HALL IC I HALL IC II VALVE Reset Five seconds after heater starts a heater will go off if the temperature by sensor is higher than 10 C Five seconds after heater starts you can confirm that a motor is moving Check if I...

Page 32: ...e display the dispenser and the control panel press and hold the LOCK button for 3 seconds The lock indicator Light is turn ON 3 The LOCK button is the only control feature that remains active in the locked state The buzzer sound other control buttons and the dispenser are deactivated 4 T o release from the locked state press and hold the LOCK button again for 3 seconds 8 1 4 Filter condition disp...

Page 33: ... for Ultra Ice and when refrigerator is overloaded Standard speeds is used for general purposes 3 T o improve cooling speed the RPM of the freezer fan motor change from normal speed to high 4 High speed 2700RPM Initial power on or load corresponding operation Ultra Ice Normal speed 2400RPM Door open conditions 5 Fan motor stops when refrigerator open 8 1 9 Cooling Fan Motor 1 The cooling fan is sw...

Page 34: ... 3 If Ultra Ice is pressed during defrost Ultra Ice LED is on but this function will start seven minutes after defrost is completed and it shall operate for three hours 4 If Ultra Ice is selected within seven minutes after compressor has stopped the compressor compressor delays seven minutes shall start after the balance of the delay time 5 The fan motor in the freezer compartment runs at high spe...

Page 35: ...such as ding will sound 3 When defect is repaired the defect code is removed and refrigerator returns to normal operation RESET 4 The Defect code is shown on the Display LED check function If simultaneously pressing Ultra Ice button and Frz Temp for a second display LED graphics on If releasing the button the LED graphic displays the previous status determinated by how often and how long the doors...

Page 36: ...tor Poor motor hooking to wires of fan contact of structures to fan snapping or short circuit of Lead wires 8 Failure of BLDC Fan Motor for Ice Maker at Freezing compartment Er IF If there is no fan motor sinal for more than 114sec in operation fan motor Poor motor hooking to wires of fan contact of structures to fan snapping or short circuit of Lead wires 9 Failure of Communication between displa...

Page 37: ...on Test MODE OPERATION FUNCTION REMARKS TEST1 TEST2 TEST3 RESET Push T est Switch in the main Board once Push TEST Switch once in TEST MODE1 Push TEST Switch once in TEST MODE 2 Push TEST Switch once in TEST MODE3 1 Continuous operation of the COMPRESSOR and the Freezer fan 2 Stepping DAMPER OPEN 3 Defrosting HEATER OFF 4 DISPLAY LED all ON 1 Continuous operation of the COMPRESSOR and the Freezer ...

Page 38: ...8 2 PCB FUNCTION 8 2 1 Power Circuit 1 Power is supplied to the control board at pin1 and 3 of connector 1 37 ...

Page 39: ...cuit A B Voltage between A B LAMP R CON 3 PIN 9 CON 3 PIN 4 115 Vac LAMP F CON 3 PIN 7 CON 3 PIN 4 115 Vac FD HTR CON 3 PIN 8 CON 3 PIN 4 115 Vac DEF HTR CON 3 PIN 10 CON 3 PIN 4 115 Vac WATER P V CON 3 PIN 11 CON 3 PIN 4 115 Vac REC COMP CON 3 PIN 12 CON 3 PIN 4 115 Vac Water P V ...

Page 40: ...lowing components Freezing compartment fan Con4 Pin1 Con4 Pin2 13 VDC 15 VDC 2 VDC or less Machine compartment fan Con4 Pin7 Con4 Pin8 13 VDC 15 VDC 2 VDC or less Icing compartment fan Con4 Pin4 Con4 Pin5 13 VDC 15 VDC 2 VDC or less FAN PIN NUMBER PIN NUMBER MOTOR ON MOTOR OFF OUTPUT VOLTAGE 39 ...

Page 41: ...OR DEFROST SENSOR ROOM SENSOR 20 ºC 4 F 22 3 K 77 K 15 C 5 F 16 9 K 60 K 10 C 14 F 13 0 K 47 3 K 5 C 23 F 10 1 K 38 4 K 0 C 32 F 7 8 K 30 K 5 C 41 F 6 2 K 24 1 K 10 C 50 F 4 9 K 19 5 K 15 C 59 F 3 9 K 15 9 K 20 C 68 F 3 1 K 13 K 25 C 77 F 2 5 K 11 K 30 C 86 F 2 0 K 8 9 K 40 C 104 F 1 4 K 6 2 K 50 C 122 F 0 8 K 4 3 K LOCATED ON DISPLAY PCB 40 PIN 1 2 3 4 5 6 7 8 9 10 11 V G F V G F V G F CONNECTOR ...

Page 42: ... 6 picture refer to page 42 41 CIRCUIT PIN NUMBER PIN NUMBER OUTPUT VOLTAGE Auger Motor Con 2 Pin 4 Con 2 Pin 3 115 VAC Solenoid Cube Con 2 Pin 12 Con 2 Pin 3 115 VAC Pilot Water Valve Con 2 Pin 11 Con 2 Pin 3 115 VAC Solenoid Dispenser Con 2 Pin 10 Con 2 Pin 3 115 VAC LEVER S W A 7 MAIN PCB 9 L N SOLENOID DISPENSER ICE MAKER HEATER 1 N 5 DOOR WATER VALVE 11 3 6 1 2 SOLENOID WATER PIPE HEATER 8 CO...

Page 43: ...urface temperature of the condenser pipe USE TEST MODE1 forced COOLING Check the amount of frost sticking on the EVAPORATOR of the Refrigerator SENSOR Check the seal when the door is closed POWER SOURCE is poor Applied voltage error CONNECTOR connection is poor TRANS FUSE is open COMPRESSOR locked or blocked OLP PTC is poor COMPRESSOR RELAY is poor THE CONNECTING WIRE is poor Refrigerant leakage F...

Page 44: ...ROSTING Check DRAIN PIPE Make sure that DEFROST SENSOR is connected Make sure that FREEZER REFRIGERATOR DOOR is closed FAN MOTOR is poor Passage of cool air is blocked EVA frozen Door liner damaged HEATER disconnection TEMPERATURE FUSE disconnection Connection is poor DEFROST SENSOR is poor HEATER RELAY is poor DRAIN PIPE is blocked Connection is poor DOOR does not close properly Make sure the DOO...

Page 45: ...8 4 MAIN PWB ASSEMBLY AND PARTS LIST 8 4 1 Main PWB Assembly 44 ...

Page 46: ...8 4 2 Dispenser Drive PWB Assembly 45 ...

Page 47: ... 401A 404A 405A 405C 405F 319E 405G 406B 409B 409B 411A 418A 501A 501F 610A 610A 619B S38 903D 903E S01 B01 B01 S22 323B 319A 319C 328B 329C 405B 405B 410G 420A 105A 307A 308A 309A 310A 312A 314A 307B 327A 317A 318A 412D 46 328A Caution Use the part number to order part not the position number 9 EXPLODED VIEW EV CASE PARTS Caution Use the part number to order part not the position number 128E 128F...

Page 48: ...131A 136A 136B 145C 145F 248E 248F 47 EV FREEZER PARTS Caution Use the part number to order part not the position number ...

Page 49: ...43F 142E 140B 170A 151A 305D 154A 155B 151A 151C 167B 140B 140D 140E S24 S24 143E 140B 140D 140E S24 S24 143E 140B 140D 140E S24 S24 143E 48 EV REFRIGERATOR PARTS Caution Use the part number to order part not the position number ...

Page 50: ...43B 243B 286A 286A 616J 627B 250A 262A 619A 615A 631A 241G 241C 241C 241C S27 S27 147A 147C 212J 244A 244A 212J 233F 233H 281D 281G 281H 249D 410C B04 B04 250B 249E 249L 250B 249M 249F 281G 281D 281H 49 249C 241F Apply on some models EV DOOR PARTS Caution Use the part number to order part not the position number ...

Page 51: ...282G 617A 113E 113F 280A 278D 500B 405H 278A 50 EV DISPENSER PARTS Caution Use the part number to order part not the position number ...

Page 52: ...600A 600B 606A 614A 630A 630C 630F 630G 630H 630K 630J 51 EV ICE MAKER PARTS Caution Use the part number to order part not the position number ...

Page 53: ... 52 617B 616B S22 623B 623C 616K 616A 625A 627C S31 619D EV VALVE WATER PARTS Caution Use the part number to order part not the position number ...

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